- Study Overview
- Simulation Setup
- Geometry
- Materials
- Boundary Conditions
- Loading
- Mesh - Simulation Steps
- Results
- Stress Analysis
- Displacement Analysis
- Other Results - Conclusions
- Appendix
- Mesh Details
- Material Properties
- References
🎯 Study Overview
- [Describe the study overview, including the expected outcomes]
Goal of the Study:
The goal is to evaluate on a simple model if the interface for steering integrated in the crown is robust enough considering the assembly and interaction with the other components. Ths evaluation, with very high safety margin should indicate if any aeras are submitted to high stress concentration so we could reinforce the initial 3D model
Key Parameters:
- Value of the Loading
- Safety Margin
- Assembly contraints that get translated to simpler model contraints
Expected Outcomes:
- We expect to see higher stresses in area with lower surface section that should therefore happen away form the studied extrusion as it is thicker than neighboring regions
- We expect raisonnable displacement that would barely exceed 10mm as stanchions would likely deform and absorb some of the stresses
🔧 Simulation Setup
Geometry
- [Describe the geometry of the model] ✅ 2025-04-24
Geometry is one of a crown with an added extrusion that allow the fixation of a connecting hardware for remote steering often seen on cargo bike. This avoid to clamp on stanchions and allow for full travel of the fork
Materials
- [Describe the boundary conditions] ✅ 2025-04-24
| Property | Value | Unit |
|---|---|---|
| Name | Aluminum 6061 | - |
| Density | 2.71 | g/cc |
| Young Modulus | 69000 | MPa |
| Poisson Ratio | 0.33 |
Boundary Conditions
- [Describe the boundary conditions] ✅ 2025-04-24
We replicate the stanchions rigidity with surface spring on both side
The interface with the steering tube is constrained as a rigid surface body, linked to a reference points at the center of gravity that allow rotation like the expected behaviour of the assembly
Loading
- [Describe the loading conditions] ✅ 2025-04-24
We apply a loading force on the reference point at the pin hole that gets transmitted to the holes surface through a rigid surface constraint
Mesh
- [Describe the mesh details] ✅ 2025-04-24
Mesh Statistics:
- Element Type: [C3D10]
- Number of Elements: [948.689]
- Number of Nodes: [1.524.903]
- Element Quality: Good
📊 Simulation Steps
- [Describe simulation steps] ✅ 2025-04-24
| Step number / title | 1 - STATIC Positive loading |
|---|---|
| Iterations for convergence | 1 |
| Convergence criteria | - |
| Notes | +1500N |
| Step number / title | 2 - STATIC Negative loading |
|---|---|
| Iterations for convergence | 1 |
| Convergence criteria | - |
| Notes | -1500N |
📈 Results
Stress Analysis
Von Mises Stress
- [Analysis of von Mises stress results] ✅ 2025-04-24
Maximum Von Mises Stress: 60.89 MPa
Stresses observed are well below any critical value that would lead to plastic deformation that usually start around 280MPa for this type of Aluminium
Displacement Analysis
- [Analysis of displacement results] ✅ 2025-04-24
For a force applied of 1500N (different to the one showed in picture before), we observe a 6.626mm displacement max
For a force applied of 2500N (different to the one showed in picture before), we observe a 11mm displacement max
🔍 Conclusions
- [Summary of the main findings] ✅ 2025-04-24
Both directions (the one of travel and the opposite of travel) were simulated with very similar results which was expected given the quasi-symmetrical geometry.
The loading values 1500N and 2500N have a very high safety factor that would only occur in brutal circumstances like a crash. They are likely overvalued as the steering rod will likely bend or slide at the interface with the steering tube before we reach such values on the crown.
The stress values are well within the elastic domain of the crown material so the current design does not show any critical area that would need revision. Also, we do not think refining the mesh on the current setup will significantly improve the results, so the confidence is high for a first evaluation.
Key Findings:
- The part is safe given the inputs
Recommendations:
- We could probably shave some weight and still be safe